Modification to Intake Manifold for Engine Cable

[Gerrha]

Here and there while going through this forum, I have noticed a few recommendations for removing a section of the intake manifold between the 4th and 5th cylinders in order to allow the manifold to be removed prior to removing the large engine cable. I am at the point in my engine rebuild so I can easily do this. The question is, are there any potential downsides to this modification?

 

[OGBeno]

No. I was the first person that I know of in the US to do this in 2007.

 

[lumbee1]

I cut my intake manifold but at a different location.
Not my picture but exactly what I did.

Thread 'FZJ80 lower intake removal by sawzall'

Jun 14, 2017

I've heard mention of cutting the lower intake manifold to remove it without disconnecting the harness on either end, etc. but have never seen pictures so I thought I'd share a few.

The story is that after pulling the head on my '97, with lower intake in place but pulled out of the way, I decided that cleaning it would be difficult and risky with it near/over the open engine. With 200k+ of carbon build up the lower intake needed to be removed and since the wiring harness is one of the more fragile things on the truck I didn't want to mess with it any more than I had to. A little...

• jpoole
• Replies: 21
• Forum: 80-Series Tech

• 

 

[Gerrha]

Very nice information. Thanks guys! I will be doing this today or tomorrow.

 

[mudgudgeon]

Very nice information. Thanks guys! I will be doing this today or tomorrow.

After feeding the cable through a couple of different times, I thought about cutting mine where @lumbee1 has cut his.
Decided it wasn't really that big a deal and decided not to cut it.

I'd be more reluctant to cut it where @OGBeno has, just because you're removing some clamping pressure on a gasket joint.

 

[OGBeno]

After feeding the cable through a couple of different times, I thought about cutting mine where @lumbee1 has cut his.
Decided it wasn't really that big a deal and decided not to cut it.

I'd be more reluctant to cut it where @OGBeno has, just because you're removing some clamping pressure on a gasket joint.

Never had issues for another decade afterwards until I scrapped the truck.

 

[Gerrha]

Finished mine earlier today and it was very easy, took less than 5-minutes with a hacksaw. Photos below.

 

[OGBeno]

Good work.

 

[Gerrha]

Good work.

Thanks!

 

[mudgudgeon]

Never had issues for another decade afterwards until I scrapped the truck.

My initial thoughts were it could affect sealing of the pressed metal gaskets, but thinking about shape of the manifolds, i guess overall they are pretty rigid.